Hybrid Barrel and Reusable  System Therefor

ABSTRACT

A barrel employs a stainless steel shell with removably mounted wooden end caps. Elongated staves are positioned in the shell. The stainless steel shell is durable and has a long life cycle. The wooden end caps are easily replaceable after each use, thus reducing long term barrel costs and saving time in barrel maintenance and care.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the priority of U.S. Provisional Patent Application No. 62/395,785 filed on Sep. 16, 2016, the disclosure of which is incorporated herein by reference in its entirety.

BACKGROUND

This invention relates generally to fermentation vessels. More particularly, this invention relates to oak barrels used for the fermentation of wine and other spirits and to methods for maintaining and recycling such barrels.

For centuries, the fermentation and aging of fruit, plants and grain substances has been undertaken in traditional wooden barrels which are typically constructed of oak. The traditional barrel has provided an excellent vessel to facilitate the natural fermentation process. In addition, the wooden materials have functioned to enhance the flavor and aesthetic qualities of the final product.

The traditional wooden barrel requires a significant quantity of wood for construction. Furthermore, the barrels require extensive barrel preparation and maintenance. The traditional barrels are also prone to leakage and susceptible to damage. The porous structure of the wood also results in a certain amount of content lost over time due to evaporation.

One conventional alternative to the conventional wooden barrel is a stainless steel barrel, which is completely sealed, requires little maintenance, is easily cleaned and is not readily damaged. A recognized disadvantage of the stainless steel barrel is the absence of the natural air exchange between the contents of the container and the environment. The steel materials also do not provide any traditional desirable flavor and aesthetic qualities to the product.

SUMMARY

Briefly stated, a barrel comprises a metal shell which extends longitudinally from a first end to a second end. A first rim-like flange is disposed at or adjacent the first end. A first wooden end cap is secured to the first flange and encloses the first end. A second rim-like flange is disposed at or adjacent the second end. A second wooden end cap is secured to the second flange and encloses the second end. A plurality of angularly spaced longitudinally extending staves are disposed in the shell. Preferably, the shell has a cylindrical shape.

An opening is defined through the shell and an adaptor having a fitting cap is disposed in the opening. At least one hoop-like retainer preferably engages the staves and secures the staves in position. Each wooden end cap has an annular recess forming a peripheral lip. The lip engages the rim-like flange. A flat head ring is positioned over each said end cap and multiple fasteners extend through each said ring, end cap and rim-like flange to secure each said end cap to the shell. The metal is preferably stainless steel and each wooden end cap is preferably oak.

In one embodiment, a barrel comprises a cylindrical steel shell which extends from a first end to a second end. A first mounting assembly removably mounts a first wooden end cap to the shell and encloses the first end. A second mounting assembly removably mounts a second wooden end cap to the shell and encloses the second end.

An opening is defined through the shell and a capped fitting is threadably disposed in the opening. A plurality of angularly spaced longitudinally extending staves are disposed in the shell and at least one hoop-like retainer engages the staves and secures the staves in fixed position against an inside surface of the shell. At least one end cap has an axially symmetric, stepped disk shape forming a peripheral lip and a central portion of enlarged thickness.

The mounting assembly comprises an annular flange which is engaged by said lip so that the central portion extends into said shell whereby said end cap is interposed between a flat ring and the annular flange. Multiple fasteners extend through the ring, the end cap and the flange to secure the end cap to the shell.

A hybrid barrel comprises a cylindrical metal shell extending longitudinally from a first end to a second end. A first right angled member is disposed at or adjacent the first end and comprises a flange and a reinforcement band extending around said shell. A first wooden end cap is removably secured to said flange and encloses the first end. A second right angled member is disposed at or adjacent second end and comprises a flange and a reinforcement band extending around said shell. A second wooden end cap is removably secured to the flange and encloses the second end. An opening is defined in the shell and a capped fitting is disposed for selective communication through the opening.

Elongated staves are disposed against the interior surface of the shell and at least one hoop-like retainer engages the staves and secures the staves in position. Each of the end caps has an annular peripheral lip. A flange projecting from the shell is engaged by the lip. Multiple threaded fasteners extend through the lip and the flange to secure the end cap to the shell.

A method for recycling a barrel comprising a metal shell and wooden end caps mounted to opposed ends of the shell comprises placing an organic material into the barrel. The organic material is processed and removed from the barrel. The wooden end caps are dismounted from the shell. New wooden end caps are mounted to the shell. The steps of introducing the material, processing the material and removing the material are repeated. The steps of dismounting the wooden end caps and mounting new end caps is also cyclically repeated.

The step of removing the wooden end caps preferably comprises removing a multiplicity of fasteners from said end cap. The step of mounting new end caps to the shell preferably comprises applying a torque to threadably secure bolts to the shell. The recycling method further comprises positioning staves in the metal shell.

The invention allows the user to have a stainless steel shell which has a long life cycle and desirable wooden end caps which are replaceable after each use, thus reducing long term costs and saving time and expense in barrel maintenance and care.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a barrel with an end cap removed therefrom;

FIG. 2 is a perspective view of the barrel of FIG. 1 with the end cap being mounted in place;

FIG. 3 is an end view of the barrel of FIG. 1;

FIG. 4 is an annotated sectional view of the barrel of FIG. 3 taken along the line 4-4 thereof;

FIG. 5 is a perspective view of an end cap for the barrel of FIG. 1; and

FIG. 6 is a functional block diagram for a barrel recycling system.

DETAILED DESCRIPTION OF THE INVENTION

With reference to the drawings wherein like numerals represent like parts throughout the several figures, a barrel which is especially adapted for the fermentation of wines and spirits is generally designated by the numeral 10. The barrel 10 is specifically constructed to replace conventional wooden barrels employed in wine making and spirit fermentation processes and preferably is dimensioned to have a volume generally commensurate with the traditional wooden barrel substantially constructed of oak.

The barrel comprises a cylindrical stainless steel shell 20 having opposed longitudinally spaced ends 22 and 24. An opening 26 is formed in a longitudinal medial location of the shell for receiving a threaded adaptor/fitting 28 having a fitting cap 29 which provides selective fluid communication with the shell interior.

A right angled metal member 30 circumscribes a portion adjacent each end 22 and 24 of the cylindrical shell and is preferably welded thereto. Each member 30 has a narrow band 32 of uniform width and a perpendicular annular flange 34. The band 32 closely subtends around the end portion of the cylindrical shell 20 to form a reinforcement band. The annular flange 34 forms a rim which radially extends at right angles to both the band 32 and the cylindrical shell 20. A multiplicity of angularly spaced openings 36 are formed around the flange 34. Although not required, the openings 36 are preferably equiangularly spaced.

A wooden end cap 40 is mounted to each of the annular flanges 34. Each end cap 40 is formed of white oak or other wooden material. Each end cap 40 has axially symmetric stepped disk-shaped form. The radially outer portion of each end cap is recessed to form an annular lip 44. As best illustrated in FIG. 5, each end cap 40 also has a plurality of angularly spaced openings 46 around the lip 44 which are generally angularly alignable with the openings 36 of the retaining flange 34. Each end cap 40 preferably has an inner planar circular surface 45 having a diameter commensurate with the inner diameter of the shell and an equidistantly spaced outer planar surface 47 having a larger diameter substantially commensurate with the diameter of the flange 34.

A pair of substantially identical steel flat head rings 50 are generally commensurate in shape and dimension to the lips 44. As best illustrated in FIG. 4, each ring 50 has angularly spaced openings 52 which are alignable with openings 36 and 46 to form a throughbore. Each end cap lip 44 is interposed between a flange 34 and a head ring 50 in sandwich fashion and their respective openings are aligned. Multiple (preferably 16 to 60) hex head bolts 60 extend through the aligned openings of the ring 50, the end cap 40 and the flange 34 and are threadably tightened to nuts 62 at the underside of flange 34 to secure and fluidly seal the end caps 40 to each of the shell ends.

Multiple elongated staves 70 are preferably arranged to angularly engage at the interior surface of the shell. The staves 70 preferably extend substantially the length of the shell and are secured by a hoop 72 which resiliently engages the staves to fix the position of the staves against the inner surface of the shell. More than one hoop 72 can be employed. The staves 70 may be formed from oak, wood or other plant material and are selected to provide flavoring and/or bouquet to the liquids to be fermented. Teflon® or wooden strips (not illustrated) may optionally be interspersed between the staves at locations 74 to hold the staves in position against the interior surface of the cylindrical shell.

It will be appreciated that the end caps 40 are secured to the ends of the shell 20 and sealed by tightening the bolts 60 so that the barrel is leak-proof. A sealing substance or gasket (not illustrated) may optionally be employed to provide a fluid-tight sealing interface between the wooden end caps 40 and the shell 20. The interior of the sealed barrel is accessed through the fitting 28.

After the contents of the barrel have been sufficiently fermented and/or aged, they are removed from the barrel via the fitting 28. The bolts 60 are loosened and the wooden end caps 40 are removed and discarded. New end caps substantially identical to wooden end caps 40 are then secured to the end of the cylindrical shell as previously described and the refurbished hybrid barrel is ready for usage.

The stainless steel shell with exteriorly exposed wooden end caps allows the contents of the barrel to exchange air. As illustrated in FIG. 4, the wooden end caps also allow the contents of the barrel to “breathe” through the wood to advantageously filter and age the contents. With a smaller surface area of wood in comparison to traditional oak barrels, the content loss due to evaporation decreases. With the removable end cap feature, cleaning and maintenance is simplified. Since stainless steel is stronger than wood, the potential for a costly filler in stave joints is effectively eliminated.

Although not preferred, it is possible that only a single wooden end cap may be employed. The opposing end cap could be made from stainless steel and permanently attached to the steel shell.

Alternative assemblies for securing an end cap to the shell could also be provided. Although it is not preferred, the end cap could have a uniform thickness without a recess/lip, and simply be bolted onto a rim-like flange 34 at each end of the shell. The outer head ring 50 is also not required, and the bolt head could directly engage or engage via an intermediate washer (not illustrated) with the wooden end cap and flange. It is also possible that U-shaped clamps or alternative fasteners could be employed to secure the removable end caps to the flange of the shell.

The stainless steel shell provides a strong durable shell for the wooden components. Processing the organic material may encompass fermenting, aging or storing the material. The wooden end caps provide the air transfer, filtering, and flavor required when fermenting, aging and storing wine and/or spirits. The stave/plant inserts provide filtering and flavor that is required when aging spirits and or wine. Additionally, while the preferred embodiment has been described primarily with respect to a stainless steel shell, additional inert, durable and strong materials can be substituted for stainless steel without departing from the inventive scope. For example, embodiments of the barrel exist with a shell of a different metallic material, including various glass-coated metals, and/or plastics. Furthermore, the exemplary cylindrical shape of the barrel or shell is non-limiting. Inventive barrels exist with an outer shell taking on different shapes, such as an ovular, rectangular prismic, or even polygon cross-sectional shape.

The first end cap is mounted onto the sheet/flange followed by the flat ring. The required amount of staves/plants are inserted into the container and secured in position with a retainer hook, Teflon® strips or wood strips. The above procedure is repeated for the other end cap, and the assembled hybrid barrel is tested with water under pressure for any possible leaks.

While preferred embodiments of the foregoing hybrid barrel and recycling system have been set forth for illustration, the foregoing description should not be deemed a limitation of the invention herein. Accordingly, various modifications, adaptations and alternatives may occur to one skilled in the art without departing from the spirit and the scope of the present invention. 

1. A barrel comprising: a metal shell extending longitudinally from a first end to a second end; a first rim-like flange disposed at or adjacent said first end; a first wooden end cap secured to said first flange and enclosing said first end; a second rim-like flange disposed at or adjacent said second end; a second wooden end cap secured to said second flange and enclosing said second end; and a plurality of angularly spaced, longitudinally extending staves disposed in said shell.
 2. The barrel of claim 1, wherein the shell has a substantially cylindrical shape.
 3. The barrel of claim 1 further comprising an opening defined through said shell and a fitting having a cap disposed at said opening.
 4. The barrel of claim 1 further comprising at least one hoop-like retainer engaging said staves and securing said staves in a fixed position.
 5. The barrel of claim 1 wherein each said end cap defines an annular recess forming a peripheral lip.
 6. The barrel of claim 5 wherein each said lip engages a flange.
 7. The barrel of claim 6 further comprising a head ring which is positioned over each said end cap and a plurality of fasteners extending through each said head ring, end cap and rim-like flange to secure each said end cap to said shell.
 8. The barrel of claim 1 wherein said metal is stainless steel and said wooden end cap is oak.
 9. A barrel comprising: a cylindrical metal shell extending longitudinally from a first end to a second end; a first wooden end cap; a first mounting assembly removably mounting said first end cap to said shell and enclosing said first end; a second wooden end cap; and a second mounting assembly removably mounting said second end cap to said shell and enclosing said second end.
 10. The barrel of claim 9 further comprising an opening defined through said shell and a capped fitting threadably disposed at said opening.
 11. The barrel of claim 9 further comprising a plurality of angularly spaced, longitudinally extending staves disposed in said shell and at least one hoop-like retainer engaging said staves and securing said staves in a fixed position against an inside surface of said shell.
 12. The barrel of claim 9 wherein said first end cap is an axially symmetric stepped disk having a peripheral lip and a central portion of larger thickness.
 13. The barrel of claim 12 wherein a said mounting assembly comprises an annular flange which is engaged by said lip so that said central portion extends into said shell and a ring wherein said end cap is interposed between said ring and said annular flange.
 14. The barrel of claim 9 wherein a said mounting assembly comprises an angled member defining a rim-like flange and a reinforcement band surrounding a portion of said shell, and further comprising a flat ring which is positioned over a said end cap, and a plurality of fasteners extending through said flat ring, said end cap and said rim-like flange to mount said end cap to said shell.
 15. A barrel comprising: a cylindrical metal shell extending longitudinally from a first end to a second end; a right angled member disposed at or adjacent said first end and comprising a flange and a reinforcement band extending around said shell; a first wooden end cap removably mounted to said flange and enclosing said first end; and a second end cap enclosing said second end.
 16. The barrel of claim 15 further comprising an opening defined through said shell and a fitting closable by a cap and disposed for selective communication through said opening.
 17. The barrel of claim 15 further comprising a plurality of staves disposed in said shell and at least one member engaging said staves and securing said staves in position.
 18. The barrel of claim 15 wherein said first wooden end cap has a stepped disk shape forming an annular peripheral lip.
 19. The barrel of claim 18 wherein said lip covers said flange.
 20. The barrel of claim 19 further comprising a flat metal member covering said lip and a plurality of fasteners extending through said flat metal member, said lip and said flange to secure said first wooden end cap to said shell.
 21. A method for recycling a barrel having wooden end caps mounted to opposed ends of a metal shell comprising: (a) placing organic material into said barrel; (b) processing said organic material; (c) removing processed organic material from said barrel; (d) dismounting wooden end caps from said metal shell; (e) mounting new end caps to opposed ends of said metal shell; and (f) repeating steps (a), (b) and (c).
 22. The recycling method of claim 21 further comprising repeating steps (d) and (e).
 23. The recycling method of claim 21 wherein step (d) further comprises removing a multiplicity of bolts securing said end caps to said metal shell.
 24. The recycling method of claim 21 wherein step (e) further comprises applying a torque to a multiplicity of bolts to secure said end caps to said shell.
 25. The recycling method of claim 21 further comprising positioning staves in said barrel. 